Optimal design of the dynamic performance of the ultra-precision fly cutting machine tool

The relative vibration displacement between the tool tip and workpiece will inevitably affect the machined surface topography during the machining process of the ultra-precision fly cutting machine tool. The dynamic performance of the rotational component consisting of the spindle, the fly cutting head, and tool holders needs to be comprehensively investigated because of its significant influences on the waviness generation on the workpiece surface. In this paper, the finite element method is adopted to establish the dynamics model of the rotational component, and then the dynamics analysis proves that the deformation of the fly cutting head and tool holders significantly affects the tool tip displacement, which is validated by a modal test and a machining test. Subsequently, three optimization schemes of the fly cutting head and three optimization schemes of the tool holder are proposed and analyzed. According to the analysis and comparison results of the dynamics response, the optimization scheme of the fly cutting head 2 and the tool holder 3 is selected as the final optimization scheme, which effectively decreases the tool tip displacement by 16.97%. The simulation results of the optimization scheme are validated by the modal test.